3EN2 FZR400 Project with FZR1000 USD + 600 Engine

[Marb]

Got my frontend from an FZR1000 in this morning. Went and got some new bearings and a few hours later i have an USD in my FZR400 :)

How i started this afternoon:



320mm disks :)



Spot the differences



And how she stands now:





Still to come on the front end:

- Powdercoated wheels in balck
- Repainted fork lowers
- Brembo brake disks
- And a WHOLE load of small things

Other things:

- The list is tooooo long

[rrsp]

have you used the original yokes ?

[cagiva996]

that looks splendid-top job!!!

[Evilchicken0]

have you used the original yokes ?

Doubt it - upside downs are a lot fatter at the top than Right ways .... I personally think the FZR 1000 (Foxeye ???) front end will be a bit heavy for the 400 but as the parts are around from your other bike whynot do it.

[Marb]

Nope, didn't use the original yokes, but the stem on the FZR1000 is exactly the same as the one on the FZR400. So it's a 1 on 1 swap. All that i had to do was mod the steeringstops a little.

The original springs are a bit tough for my 400, but keep in mind that i am just under 100kilo and 187cm. FZR1000 forks standard have 15W oil in them, and now they have 10W oil in them. However need to go out and have a ride to test them. Atm it just looks 200% beter, if it improves steering and damping by 50% im happy.

Got some more toys today :D











EDIT: Maybe some useful info for the FZR enthusiats around here.

The FZR 400, FZR600 and FZR1000 all have the same bearing sizes, which means that the forks are interchangeable.



f.l.t.r- FZR400/FZR600/FZR1000

The FZR400 and 600 have the same steering stops.

[Evilchicken0]

Cool ... that's interesting - you can see the difference between the 41mm (400 3en2) and 38mm (600) forks in the last pic.

Rearsets look nice and the 1000 master cylinder looks similar to the TJ master but I suspect it's a 20 ratio.

[Marb]

Yup, the 600 has damn skinny forks compared to the 3EN2 en and the FZR1000.

The mastercilinder is off a 600R (4JH), so i wouldnt be suprised if it was the same as the 3TJ. Makes quite a difference, not really in brake power but much more feel because i can finally reach the handel with my small fingers :)

Just out of interest. I had bought new bearings for the FZR1000, but i had the hardest time removing the bottom bearing. I ended up welding it, which caused it to expand rappidly, and while still hot with a chisel knock it off. I assume there is some sort of expensive special tool that i am missing. How do you guys do it?

This is what the old bearing looked liek after my abuse. The new one went on real smooth.

[fzr6]

good effort.

be interesting to see how the handling is affected.

[plodder]

I've got a set of them USD forks, yokes, clipons, spindle & wheel for sale if anyone's interested.

I've got disks too but not in very good condition.

[Marb]

Might as wel post my other mods here then. About half a year ago i bought a complete FZR600 for very little without fairings, as a donor for my FZR400/600 conversion. So one cold but clear febuary morning went to pick up the FZR in my Jetta, and yes, a complete FZR fits in Jetta:





Prepped my FZR400 to take the FZR600 lump:



And about half a hour and four cigs later we have an FZR600 in my 400:





Some small problem immediatly show up. The oil cooler has some clearing problems (wel did then with the other forks in it, dont know with the USD now)



And the FZR600 headers didnt clear the rear-sets



However when i wanted to change the oil i was in for a nasty suprise



Most probably a blown head gasket

So pulled out the 600 lump again and prepped the 400 lump to go back in so that at least i can ride around



Then started pulling apart the 600 lump

Before:







After (skimmed head)







Valves:













And a few friends came to help out